Method for manufacturing a housing element having a decorative covering and a grip layer

Abstract

A housing element of a product includes a foil having a decorated side, where this decorated side of the foil is covered by a grip layer for realizing a grip effect. The other side of the foil is covered by a supportive layer. The grip layer may have a rib structure. Each of the supportive layer and the grip layer is applied to the foil in an injection molding process. A processing temperature of the material of the grip layer is significantly lower than an activation temperature of printing ink of a decorative covering of the foil, so that washout of the printing ink is prevented. Further, material of an adhesive layer of the foil is configured to establish adhesion to the material of the grip layer at this relatively low temperature.

The invention claimed is: 
     
       1. A method for manufacturing an element which is intended to be applied as a part of a product for a domestic appliance, the method comprising the following acts of:
 providing a foil having a decorated side; 
 applying a supportive layer of a first material to another side of the foil than the decorated side; 
 applying a grip layer of a second material to the decorated side of the foil; and 
 providing elongated interruptions in the grip layer, the elongated interruptions providing access to the foil; 
 wherein the foil comprises a base foil and a decorative covering, and wherein the providing act includes sub-acts of 
 providing the base foil; 
 applying the decorative covering comprising at least two color layers of coloring material to a decorated side of the base foil, wherein the two color layers include an inner color layer contacting the base foil and an outer color layer formed over the inner color layer; and 
 forming a window in the inner color layer configured to let light pass from the supportive layer to the outer color layer for scattering by the outer color layer and the grip layer. 
 
     
     
       2. The method according to  claim 1 , wherein a material which, in a solidified state, is softer than the first material for forming the supportive layer is used as the second material for forming the grip layer. 
     
     
       3. The method according to  claim 1 , wherein a material which, in a solidified state, has a hardness of lower than 70 Shore A is used as the second material for forming the grip layer. 
     
     
       4. The method according to  claim 1 , wherein a translucent material is used as the second material for forming the grip layer. 
     
     
       5. The method according to  claim 1 , wherein, prior to the acts of applying the supportive layer and the grip layer, the foil is given a predetermined shape. 
     
     
       6. The method according to  claim 1 , wherein the act of applying the supportive layer to the foil is carried out by placing the foil in a mold for injection molding, introducing the first material into the mold, in a liquefied state, and allowing the liquid material to solidify. 
     
     
       7. The method according to  claim 1 , wherein the act of applying the grip layer to the foil having the supportive layer is carried out by placing the foil having the supportive layer in a mold for injection molding, introducing the second material into the mold, in a liquefied state, and allowing the liquid material to solidify. 
     
     
       8. The method of  claim 1 , wherein the act of providing the foil comprises the act of:
 applying an adhesive layer on top of the decorative covering, wherein the adhesive layer comprises a binder material having an activation temperature which is lower than an activation temperature of the coloring material of one color layer of the at least two color layers. 
 
     
     
       9. The method of  claim 8 , wherein the activation temperature of the coloring material is above 260° C., and wherein the activation temperature of the binder material is below 200° C. 
     
     
       10. The method of  claim 8 , wherein the first color layer is black. 
     
     
       11. The method of  claim 1 , wherein the first material of the supportive layer is softer than the second material of the grip layer. 
     
     
       12. The method of  claim 1 , wherein the act of providing the foil further comprises the act of applying an adhesive layer on top of the outer color layer, wherein the adhesive layer comprises a binder material having an activation temperature which is lower than an activation temperature of the coloring material of the at least two color layers of the decorative covering. 
     
     
       13. The method of  claim 1 , wherein the grip layer includes ribs located between the elongated interruptions, and wherein the forming act forms the window below one of the ribs.